Welding Shop

What is Welding Shop?

Welding is a fabrication or sculptural process that joins materials, usually metals or

thermoplastics, by using high heat to melt the parts together and allowing them to cool
causing fusion. Welding also requires a form of shield to protect the filler metals or melted
metals from being contaminated or oxidized .Welding is a fabrication or sculptural process
that joins materials, usually metals or thermoplastics, by using high heat to melt the parts
together and allowing them to cool causing fusion. Welding also requires a form of shield to
protect the filler metals or melted metals from being contaminated or oxidized.

Types of Welding:

There are many types of welding, but major types of welding are as following:

 MIG Welding
 Stick Welding
 TIG Welding
 Plasma Arc Welding
 Electron Beam Welding
 Laser Welding
 GAS Welding
 GMA Welding
 GTA Welding
 Electric Arc Welding
 Resistance Welding
1) MIG Welding:

Gas metal arc welding (GMAW), also known as MIG (metal inert
gas) welding or MAG (metal active gas) welding, is a process in which an
electric arc forms between an electrode and a metal work piece, heating the
metals and causing them to melt, and be joined.

2) Stick Welding:

Stick welding is a form of welding that uses electricity to melt a metal filler
rod/electrode/stick (electrode is the proper term) that melts both the metal joint
and electrode all at once to fuse two pieces of metal together and fill the joint
with filler metal at the same time.
3) TIG Welding:

TIG welding for motor sports .TIG stands for tungsten inert gas and is
technically called gas tungsten arc welding (GTAW). The process uses a non-
consumable tungsten electrode that delivers the current to the welding arc. The
tungsten and weld puddle are protected and cooled with an inert gas, typically
argon.

4) Plasma Arc Welding:

Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc
welding (GTAW). The electric arc is formed between an electrode (which is
usually but not always made of sintered tungsten) and the work piece.

5) Electron Beam Welding:

Electron-beam welding is a fusion welding process in which a beam of high-

velocity electrons is applied to two materials to be joined. The work pieces melt
and flow together as the kinetic energy of the electrons is transformed into heat
upon impact.
6) Laser Beam Welding:

Laser beam welding is a welding technique used to join pieces of metal or

thermoplastics through the use of a laser. The beam provides a concentrated heat
source, allowing for narrow, deep welds and high welding rates.

7) Gas Welding:

Metal joining process in which the ends of pieces to be joined are heated at their
interface by producing coalescence with one or more gas flames (such as oxygen
and acetylene), with or without the use of a filler metal
8) GMA Welding:

Gas metal arc welding, sometimes referred to by its subtypes metal inert gas
welding or metal active gas welding, is a welding process in which an electric
arc forms between a consumable MIG wire electrode and the work piece metal,
which heats the work piece metal, causing them to melt and join.

9) GTA Welding:

Gas tungsten arc welding, also known as tungsten inert gas welding, is an arc
welding process that uses a non-consumable tungsten electrode to produce the
weld.
 10) Electric Arc Welding:
It is a type of welding that uses a welding power supply to create an electric arc
between a metal stick ("electrode") and the base material to melt the metals at the
point of contact. Arc welders can use either direct (DC) or alternating (AC) current,
and consumable or non-consumable electrodes.

11) Resistance Welding:

Electric resistance welding refers to a group of welding processes such as spot

and seam welding that produce coalescence of faying surfaces where heat to
form the weld is generated by the electrical resistance of material combined
with the time and the force used to hold the materials together during welding

Types of Resistance Welding:

 Spot Welding
 Seam Welding
1) Spot Welding

Resistance spot welding is a process in which contacting metal surface points are
joined by the heat obtained from resistance to electric current. It is a subset of electric
resistance welding. Work-pieces are held together under pressure exerted by
electrodes

2) Seam Welding:
Seam welding is a variation of resistance spot welding. In resistance seam welding,
however, the welding electrodes are motor driven wheels as opposed to stationary
rods. The result is a 'rolling' resistance weld or non-hermetic seam weld.
Defects of Welding:

The defects in the weld can be defined as irregularities in the weld metal produced due to
incorrect welding parameters or wrong welding procedures or wrong combination of filler
metal and parent metal. It can simply be defined as:

“Defects introduced during welding beyond the acceptance limit that can cause a weld to
fail”. A defect does not allow the finished joint to withstand the required strength (load).

Welding defects can be classified into two types as external and internal defects:

External Welding Defects:

1) Weld Crack

2) Undercut

3) Spatter

4) Porosity

5) Overlap

6) Crater

Internal Welding Defects:

1) Slag Inclusion

2) Incomplete Fusion

3) Necklace cracking

4) Incomplete penetration
External Welding Defects
The various types of external defects with their causes and remedies are listed below:

1) Weld Crack:
This is the most unwanted defect of all the other welding defects. Welding cracks can
be present at the surface, inside of the weld material or at the heat affected zones.

2) Undercut:
When the base of metal melts away from the weld zone, then a groove is formed in
the shape of a notch, then this type of defect is known as Undercut. It reduces the
fatigue strength of the joint.

3) Spatter:
When some metal drops are expelled from the weld and remain stuck to the surface,
then this defect is known as Spatter.
 4) Porosity
Porosity in the condition in which the gas or small bubbles gets trapped in the welded
zone

5) Overlap:
When the weld face extends beyond the weld toe, then this defect occurs. In this
condition the weld metal rolls and forms an angle less than 90 degrees.

6) Crater:
It occurs when the crater is not filled before the arc is broken, which causes the outer
edges to cool faster than the crater. This causes a stress and then crack is formed.
Internal Welding Defects
The various types of internal welding defects with their causes and remedies are listed below:

1) Slag Inclusion:
If there is any slag in the weld, then it affects the toughness and metal weld ability of
the given material. This decreases the structural performance of the weld material.
Slag is formed on the surface of the weld or between the welding turns.

2) Incomplete Fusion:
Incomplete fusion occurs when the welder does not accurately weld the material and
the metal pre solidifies which leads to a gap which is not filled with the molten metal.

3) Necklace Cracking:
It occurs in the use of electron beam welding where the weld does not penetrate
properly. Therefore, the molten metal does not flow into the cavity and results in a
cracking known as “Necklace Cracking”.
 4) Incomplete Penetration:
These defects occur only in the butt welds where the groove of the metal is not filled
completely. It is also called as incomplete penetration defect.

Different Types of Welding Joints:

Welding joints is an edge or point where two or more metal pieces or plastic pieces are joined
together. The two or more work pieces (either metal or plastic) are joined with the help of a
suitable welding process to form a strong joint. According to the American Welding Society,
there are basically five types of welding joints and these are Butt, Corner, Lap, Tee and edge
joint.
The 5 basic welding joints are
1. Butt joint
2. Corner joint
3. Lap joint
4. Tee joint and

1) Butt Joint:
The joint which is formed by placing the ends of two parts together is called butt
joint. In butt joint the two parts are lie on the same plane or side by side. It is the
simplest type of joint used to join metal or plastic parts together.
2) Corner Joint:
The joint formed by placing the corner of two parts at right angle is called corner joint
(see fig above). Two parts which is going to be weld with corner joint forms the shape
of L.

3) T-Joint:
The joint which is made by intersecting two parts at right angle (i.e at 90 degree) and
one part lies at the centre of the other. It is called as T joint as the two part welded
look like English letter ‘T’.

4) Lap Joint:
The lap joint is formed when the two parts are placed one over another and than
welded (see fig above). It may one sided or double sided. These types of welding
joints are mostly used to join two pieces with different thickness.
5) Edge Joint:
The joint formed by welding the edges of two parts together are called edge joint. This joint
is used where the edges of two sheets are adjacent and are approximately parallel planes at
the point of welding. In this joint the weld does not penetrates completely the thickness of
joint, so it cannot be used in stress and pressure application.

Advantages of Welding:

1) As no hole is required for welding, hence no reduction of area. So structural members

are more effective in taking the load.
2) In welding filler plates, gusseted plates, connecting angles etc, are not used, which
leads to reduced overall weight of the structure.
3) Welded joints are more economical as less labor and less material is required.
4) The efficiency of welded joint is more than that of the riveted joint.
5) The welded joints look better than the bulky riveted/butted joints.
6) The speed of fabrication is faster in comparison with the riveted joints.
7) Complete rigid joints can be provided with welding process.
8) The alternation and addition to the existing structure is easy.
9) No noise is produced during the welding process as in the case of riveting.
10) The welding process requires less work space in comparison to riveting.
11) Any space of joint can be made with ease.
Disadvantages of Welding:

1) Welded joints are more brittle and therefore their fatigue strength is less than the
members joined.
2) Due to uneven heating & cooling of the members during the welding, the members
may distort resulting in additional stresses.
3) Skilled labor and electricity are required for welding.
4) No provision for expansion and contraction is kept in welded connection & therefore,
there is possibility of racks.
5) The inspection of welding work is more difficult and costlier than the riveting work.
6) Defects like internal air pocket, slag inclusion and incomplete penetration are difficult
to detect.